Stellar Flex36 User Manual

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OWNER’S MANUAL

Safety, Installation, Maintenance, and Operation

Stellar Flex36 Hooklift

Models

60-8

84-10 108-12 120-14

Stellar Industries, Inc.

190 State Street

PO Box 169

Garner, IA 50438

800-321-3741

Fax: 641-923-2811

www.stellarindustries.com

Manual Part No. 35551 Last Revision: 10/03/07

Flex36 Hooklift Manual Revisions

Date of Revision

August 27, 2007

Section Revised

Chapter 6 - Installation

Description of Revision

Updated Reservoir Assembly Drawing (PN 35883) to reflect engineering changes.

Table of Contents

Table of Contents i

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii

Stellar Flex Hooklift Nomenclature . . . . . . .iv

Chapter 1 - Safety . . . . . . . . . . . . . . . . . . . . . .1

General Safety . . . . . . . . . . . . . . . . . . . . . . .1

Personal Safety . . . . . . . . . . . . . . . . . . . . . . .1

Maintenance Safety . . . . . . . . . . . . . . . . . .1

Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Load Safety . . . . . . . . . . . . . . . . . . . . . . . . . .2

Environment . . . . . . . . . . . . . . . . . . . . . . . . . .2

Chapter 2 - Operation . . . . . . . . . . . . . . . . . . .3

Job-Site Set-Up . . . . . . . . . . . . . . . . . . . . . . .3

Operator Requirements . . . . . . . . . . . . . . . .3

Operator Conduct . . . . . . . . . . . . . . . . . . . .3

Hooklift Controls . . . . . . . . . . . . . . . . . . . . . .4

Operation Overview . . . . . . . . . . . . . . . . . . .4

Unloading Operation . . . . . . . . . . . . . . . . . .5

Loading Operation . . . . . . . . . . . . . . . . . . . .6

Dumping Operation . . . . . . . . . . . . . . . . . . .7

Chapter 3 - Maintenance . . . . . . . . . . . . . . . .9

Maintenance Procedures . . . . . . . . . . . . . .9

Periodic Inspection . . . . . . . . . . . . . . . . .9

Daily Inspection

Monthly Inspection . . . . . . . . . . . . . . . . .9

General Service . . . . . . . . . . . . . . . . . . . .9

Choice Lubricants for DX Bearings . . . . . .10

Chapter 4 - Specifications . . . . . . . . . . . . . .11

Stellar Flex36 Model 60-8

Hydraulic Hooklift Specifications . . . . .12

Stellar Flex36 Model 84-10

Hydraulic Hooklift Specifications

Stellar Flex36 Model 108-12

Hydraulic Hooklift Specifications . . . . .14

Stellar Flex36 Model 120-14

Hydraulic Hooklift Specifications . . . . .15

Chapter 5 - Decals . . . . . . . . . . . . . . . . . . . .17

Decals of Note . . . . . . . . . . . . . . . . . . . . . .17

Decal Kit Placement - PN 35559 . . . . . . . .18

Chapter 6 - Installation . . . . . . . . . . . . . . . . .19

Basic Installation Overview Installation Steps - Basic Guidelines Mounting Kit (Model 60-8) - PN 33320 . . .22 Mounting Kit (Models 84-10, 108-12,

120-14) - PN 23700

Rotary Valve

(All Models) - PN 37741 . . . . . . . . . . . . .24

Reservoir Assembly - PN 35883 . . . . . . . . .25

Setting System Relief Pressure . . . . . . . . .26

Installation Instructions for the

. . . . . . . . . . . . . . . . . . . .9

. . . . .

. . . . . . . . . . . .

. . . . .

. . . . . . . . . . . . . . . . .

19 20

Power Beyond VDM8 Valve . . . . . . . . .28

Port Side Relief Installation . . . . . . . . . . . . .29

Controller Assembly - PN 38841 . . . . . . . .30

Dump Light Kit Installation . . . . . . . . . . . . .31

Hydraulic Schematic

(Model 60-8) - PN 34616 . . . . . . . . . . . .32

Hydraulic Schematic

(Model 84-10)- PN 34617 . . . . . . . . . . . .33

Hydraulic Schematic

(Model 108-12) - PN 34618 . . . . . . . . . .34

Hydraulic Schematic

(Model 120-14)- PN 34619 . . . . . . . . . . .35

Subframe Model 60-8 . . . . . . . . . . . . . . . . .36

Subframe Model 84-10 . . . . . . . . . . . . . . . .37

Subframe Model 108-12 . . . . . . . . . . . . . . .38

Subframe Model 120-14 . . . . . . . . . . . . . . .39

Chapter 7 - Assembly Drawings . . . . . . . . . .41

Base Assembly (60-8) - PN 31823 . . . . . . .41

Base Assembly (84-10) - PN 33337 . . . . . .42

Base Assembly (108-12) - PN 34245 . . . . .43

Base Assembly (120-14) - PN 33419 . . . . .44

Dump Assembly (60-8) - PN 31824

Dump Assembly (84-10) - PN 33339 . . . . .46

Dump Assembly (108-12) - PN 34247 . . . .47

Dump Assembly (120-14) - PN 33417 . . . .48

Secondary Assembly

(60-8) - PN 33047 . . . . . . . . . . . . . . . . . .49

Secondary Assembly

(84-10) - PN 33341 . . . . . . . . . . . . . . . . .50

Secondary Assembly

(108-12) - PN 34249 . . . . . . . . . . . . . . . .51

Secondary Assembly

(120-14) - PN 33415 . . . . . . . . . . . . . . . .52

Tilt Assembly

(All Flex36 Models) - PN 33049 . . . . . . .53

Tilt Assembly

(Optional Tall Tilt) - PN 35032 . . . . . . . .54

Tilt Cylinder Assembly

(All Flex36 Models) - PN 23460 Main Cylinder Assembly

(60-8) - PN 27116 . . . . . . . . . . . . . . . . . .56

Main Cylinder Assembly

(84-10)- PN 33404 Main Cylinder Assembly

(108-12, 120-14)- PN 33462 . . . . . . . . . .58

Chapter 8 - Replacement Parts . . . . . . . . . .59

Chapter 9 - Troubleshooting . . . . . . . . . . . . .61

Warranty Information . . . . . . . . . . . . . . . . . . .62

. . . . . . . . . . . . . . . . . .

. . . . . .45

. . . . . . .

ii Flex36 Owner’s Manual

AN OVERVIEW TO OWNER, OPERATOR AND

SERVICE PERSONNEL ABOUT SAFETY

As the owner or employer, it is your responsibility to instruct the operator in the safe operation of this equipment and to provide the operator with properly maintained equipment.

FAILURE TO READ THIS MANUAL BY ANYONE WHO WILL OPERATE, SERVICE, OR WORK AROUND THIS HOOKLIFT IS A MISUSE OF THE EQUIPMENT. DEATH OR SERIOUS INJURY WILL RESULT FROM IMPROPER USE OR MAINTENANCE OF THIS MACHINE.

Occupational safety is a prime concern of Stellar Industries in the design and production of this hooklift. Our goal in writing this manual was the safety of the operator and others who work around this equipment.

It is your responsibility to know the specific requirements, governmental regulations, precautions and work hazards that exist in the operation and maintenance of this hooklift. You shall make these available and known to all personnel working with and around the equipment, so that all of you will take the necessary and requir

FAILURE TO HEED THESE INSTRUCTIONS CAN RESULT IN SERIOUS INJURY OR DEATH.

ed safety precautions.

It is also your responsibility to operate and maintain your hooklift with caution, skill, and good judgment. Following the recognized safety procedures will help you avoid accidents. Modification to any part of his hooklift can create a safety hazard and therefore shall not be made without the manufacturer’s written approval. Use only factory approved accessories, options, and parts on this equipment. The rebuilding or remounting of this equipment requires the mounting procedures and retesting to be in accordance with factory instructions. Safety covers and devices must remain installed and maintained in proper working condition. Safety decals must be maintained, be completely legible, and be properly located. If safety covers, devices, or decals are missing, they must be replaced with the proper designated Stellar part.

Be capable, careful, and concerned! Make safety your everyday business!

Attention!

According to Federal Law (49 cfr part 571), each final-stage manufacturer shall complete the vehicle in such a manner that it conforms to the standar date of manufacture of the incomplete vehicle, the date of final completion, or a date between those two dates. This requirement shall, however, be superseded by any conflicting provisions of a standard that applies by its terms to vehicles manufactured in two or more stages. Therefore, the installer of Stellar hooklifts is considered one of the manufacturers of the vehicle. As such a manufacturer

ds in ef

fect on the

, the

installer is responsible for compliance with all applicable federal and state regulations. They are required to certify that the vehicle is in compliance with the Federal Motor Vehicle Safety Standards and other regulations issued under the National Traffic and Motor Vehicle Safety Act.

ence the Code of Federal

Please r Regulations, title 49 - Transportation, Volume 5 (400-999), for further information, or visit www.gpoaccess.gov/nara/index.html for the full text of Code of Federal Regulations.

efer

Introduction

Introduction iii

Stellar Hooklifts are designed to provide safe and dependable service for a variety of operations. With proper use and maintenance, these hooklifts will operate at peak performance for many years.

To promote this longevity, carefully study the information contained in this manual before putting the equipment into service. Though it is not intended to be a training manual for beginners, this manual should provide solid guidelines for the safe and proper usage of the hooklift.

Once you feel comfortable with the material contained in this manual, strive to

cise your knowledge as you safely

exer operate and maintain the hooklift. This process is vital to the proper use of the unit.

A few notes on this manual:

A copy of this manual is provided with every hooklift and shall remain with the hooklift at all times. Information contained within this manual does not cover all maintenance, operating, or repair instructions pertinent to all possible situations.

Please be awar manual contain information pertaining to

e that some sections of this

Stellar manufactured hooklifts in general and may or may not apply to your specific model.

This manual is not binding. Stellar Industries, Inc. reserves the right to change, at any time, any or all of the items, components, and parts deemed necessary for product improvement or commercial/production purposes. This right is kept with no requirement or obligation for immediate mandatory updating of this manual.

In closing:

If more information is required or technical assistance is needed, or if you feel that any part of this manual is unclear or incorrect, please contact the Stellar Customer Service Department by phone at 800-321-3741 or email at service@stellarindustries.com.

ATTENTION

Failure to adhere to the

instructions could result in

property damage or even serious

bodily injury to the operator or

others close to the hooklift.

For Technical Questions, Information, Parts, or Warranty, Call Toll-Free at

800-321-3741

Hours: Monday - Friday, 8:00 a.m. - 5:00 p.m. CST

Or email at the following addresses:

Technical Questions, and Information service@stellarindustries.com

Order Parts parts@stellarindustries.com

Warranty Information warranty@stellarindustries.com

iv Flex36 Owner’s Manual

HOOKLIFT

BASE

DUMP

SECONDARY

TILT

Stellar Flex Hooklift Nomenclature

The Stellar Flex is a hydraulic, body-loading device when mounted on a truck chassis. When mounted, the Stellar Flex can handle a variety of bodies ranging from flatbeds to recycling containers to dump bodies.

Two independently controlled cylinders operate all the functions of the Stellar Flex. By varying the cylinder operation, the Stellar Flex can be used to dump or unload a body.

The Stellar Flex consists of four basic parts: The base, dump, secondary, and tilt sections. Familiarize yourself with the various components of this hooklift and the names of those components. Knowing the proper terminology is necessary to get full benefit from this manual

Chapter 1 - Safety

Safety 1

Please Read the Following Carefully! This portion of the manual contains information regarding all Stellar manufactured hooklifts. Some items contained within this chapter may not apply to your specific equipment.

Safety should be the number one thought on every operator’s mind. Three factors should exist for safe operation: a qualified operator, well-maintained equipment, and the proper use of this equipment. The following information should be read and understood completely by everyone working with or near the hooklift before putting the unit into operation.

Please take note that Stellar Industries, Inc. is not liable for accidents incurred by the hooklift because of non-fulfillment from the operator’s side of current rules, laws, and regulations.

General Safety

It is the responsibility of the owner to instruct the operator in the safe operation of your equipment and to provide the operator with properly maintained equipment.

anti-noise headphones, protective glasses, breathing apparatus, and reflective jackets. Consult your employer regarding current safety regulations and accident-prevention equipment.

Do not wear rings, wristwatch, jewelry, loosefitting or hanging clothing such as ties, torn garments, scarves, unbuttoned jackets or unzipped overalls, which could get caught up in the moving parts of the hooklift.

Keep a first-aid box and a fire extinguisher readily available on the truck. Regularly check to make sure the fire extinguisher is fully charged and the first-aid kit is stocked.

Do not use controls and hoses as handholds. These parts move and cannot provide stable support.

Do not allow unauthorized personnel or equipment to enter within 10 feet of hooklift operating area.

Never allow anyone to ride the hooklift or load.

Trainees or untrained persons shall be under the direct supervision of qualified persons.

Do not operate equipment under the adverse influence of alcohol, drugs, or medication.

Read all Danger and Caution decals on the equipment and understand their meaning.

Personal Safety

Keep clear of all moving parts.

Always wear the pr devices.

Always wear appr clothing such as: protective helmets, antislip shoes with steel toes, protective gloves,

escribed personal safety

oved accident-prevention

Maintenance Safety

Never modify or alter any of the equipment, whether mechanical, electrical, or hydraulic, without Stellar Industries’ approval.

Do not perform any maintenance or repair work on the hooklift unless authorized and trained to do so. Release system pressure before attempting to make adjustments or repairs.

Do not attempt service or repair when PTO is engaged.

Decals are considered safety equipment. They must be maintained, as would other safety devices. Do not remove any decals.

2 Flex36 Owner’s Manual

Replace any decals that are missing, damaged, or not legible.

The safety instruction plates, notices, load charts and any other sticker applied to the hooklift must be kept legible and in good condition. If necessary, replace them.

Keep all surfaces of the hooklift free of oil and grease to avoid slippery surfaces and aid in inspections.

Stability

Know the hooklift components and their capabilities and limitations. Overloading the hooklift may result in serious damage of self, others, equipment or the surroundings.

Never exceed manufacturer’s load ratings. These ratings are based on the machine’s hydraulic, mechanical, and structural design rather than stability.

Load Safety

Full rated dump capacity assumes load will decrease as dump angle increases. Do not take full rated capacity to full dump angle without some unloading of weight as it may cause damage to the chassis and/or the hooklift.

Move the control lever slow and smooth for steady oil flow.

Avoid jerky or sudden movement of the controls.

weight can be lifted.

Keep everyone clear when loading, unloading, and dumping.

Do not push on fixed objects or bodies without rollers with the hooklift.

Do not permit loose objects on the hooklift.

Use a qualified person to assist in loading when the load is not visible to the operator.

Do not leave hooklift unattended with suspended load.

Take care when operating in areas supported by vehicle tires, because of the cushioning effect of springs and tires.

Never use the drivetrain of the chassis to assist the hydraulics in loading

Environment

Do not operate the hooklift during electrical storms.

In extreme cold, allow adequate time to warm the truck before engaging the PTO. Do not rev the truck engine and over speed the hydraulic pumps as permanent damage to the pumps may occur. Follow the vehicle owner’s manual regarding operating the vehicle in such adverse conditions.

In extreme cold, operate the controls slowly to allow for viscosity changes.

Be constantly aware of the hooklift position when operating the controls.

Do not attempt to lift fixed loads. Know the weight of your load to avoid overloading the equipment.

Deduct the weight of the body from the maximum load rating to determine how much

ATTENTION

Stellar Industries, Inc. is not liable

for accidents incurred by the

hooklift because of the

operator’s non-fulfillment of

current rules, laws and

regulations.

Chapter 2 - Operation

Operation 3

Job-Site Set-Up

Thoroughly plan the lift before positioning the vehicle. Consider the following:

1. The vehicle should be positioned in an area free from overhead obstructions to eliminate the need for repositioning.

2. Position the vehicle so that it is impossible for any portion of the equipment to come within the minimum required safe distance of any power line. Maintain a clearance of at least 10 feet between any part of the hooklift, load line, or load, and any electrical line or apparatus carrying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less. Remember to allow for winds that cause power lines to sway. It is recommended that a signal person be used when the vehicle is set-up near power lines.

3. The vehicle should also be positioned on a firm and level surface that will provide adequate support for the body.

Operator Requirements

Operation is limited to the following people: A. Qualified individual. B. Trainees under direct supervision of the

qualified individual. C. Test or maintenance individual. D. Hooklift Inspector.

Operators must: A. Demonstrate the ability to understand

all decals, the owner’s manual, and any other information required for safe operation of the hooklift.

B. Be able to demonstrate the ability to

safely control the hooklift. C. Know all safety r D. Be responsible for maintenance require-

ments.

E. Understand and be fully capable of

implementing all emergency proce-

dures. F. Understand the operating procedures as

outlined by this manual, Ansi B30.5 and Federal/State Laws.

egulations.

4. The parking brake must be removed to allow the truck to roll under the body while loading.

CAUTION

When loading and unloading bodies, the tilt cylinder must be fully extended before operating the lift cylinder to prevent damage to the latch systems.

2. When the PTO is engaged, do not run the engine over 1400 RPM.

3. Do not hold the brakes while performing operations.

Operator Conduct

1. Operators will not engage in any operation that would cause them to divert attention away fr the hooklift.

2. Operators are responsible for all opera tions under their direct control.

3. Operators will not leave a suspended load unattended.

4. Operators will be familiar with the equipment and the maintenance required for

oper care.

om the operation of

4 Flex36 Owner’s Manual

Hooklift Controls

1. Be familiar with the sequence and operation of the hooklift controls.

2. Each individual hooklift function should have control function decals. Replace them immediately if they are missing or illegible.

3. Keep hands, feet and control levers free from mud, grease and oil.

4. Be familiar with the control levers and how they operate before attempting to operate the hooklift.

5. Be prepared before beginning operation of the hooklift:

• All pr

•

• Be sure all safety devices provided are

• Be prepared for all situations. Keep

• Be sure all regular maintenance has

• Visually inspect all aspects of the

• Check for fluid leaks.

otective guards must be in place. Be aware of the surroundings: low branches, power lines, unstable ground.

in place and in good operating condition.

fire extinguisher and first aid kit near.

been performed.

hooklift for physical damage.

Operation Overview

Unloading Operation

. Stop the truck at the location you wish to unload.

2. Put the truck in neutral and engage the PTO. Run RPM as needed.

3. Locate the black control lever labeled tilt.

4. Pull the tilt lever until the cylinder is fully extended, thus releasing tabs.

5. Locate the red lever labeled lift.

6. Pull lift lever until the body is on the ground and can be detached. Return the hooklift to the stored position and disengage the PTO.

Loading Operation

1. Position the truck in line with the body you intent to pick up.

2. Engage the hook to the body by maneuvering the hooklift with the red(lift) lever. Run RPM as needed.

3. Push the red(lift) lever until the main cylinder is fully retracted.

4. Push the black(tilt) lever until the tilt is fully extended.

5. Disengage the PTO.

NOTE: The controller assembly pictured in this

chapter may differ from model to model.

Dumping Operation

1. Stop the truck at the location you wish to dump the load.

2. Put the truck in neutral and engage the PTO. Run RPM as needed.

3. Locate the red lever labeled lift.

4. Pull the lever to dump the body.

5.Wait until dumping is complete, then push the

red(lift) lever until the main cylinder fully retracts.

6. Disengage the PTO.

Unloading Operation

5Operation 5

1. Stop the truck at the location you wish to unload.

3. Locate the black control lever labeled tilt.

2. Put the truck in neutral and engage the PTO. Run RPM as needed.

4. Pull the tilt lever until the cylinder is fully extended, thus releasing tabs.

5. Locate the r

ed lever labeled lift.

6. Pull lift lever until the body is on the ground and can be detached. Return the hooklift to the

stored position and disengage the PTO.

6 Flex36 Owner’s Manual

Loading Operation

1. Position the truck in line with the body you intent to pick up.

3. Push the red(lift) lever until the main cylinder is fully retracted.

2. Engage the hook to the body by maneuvering the hooklift with the red(lift) lever.

Run RPM as needed.

4. Push the black(tilt) lever until the tilt is fully retracted.

5. Disengage the PTO.

Dumping Operation

7Operation 7

1. Stop the truck at the location you wish to dump the load.

3. Locate the red lever labeled lift.

2. Put the truck in neutral and engage the PTO. Run RPM as needed.

4. Pull the lift lever to dump the body.

5. Wait until dumping is complete, then push the ed(lift) lever until the main cylinder fully r

etracts.

6. Disengage the PTO.

8 Flex36 Owner’s Manual

Chapter 3 - Maintenance

9Maintenance 9

Please read the following before performing any m

aintenance on the hooklift.

1. Only authorized service personnel are to perform maintenance on the hooklift.

2. Disengage the PTO before any service or repair is performed.

3. Do not disconnect hydraulic hoses while there is still pressure in those components.

4. Before disconnecting hydraulic components, shut off the engine, release any air pressure on the hydraulic reservoir, and move control levers repeatedly through their operating positions to relieve all pressures. Keep the hooklift clean and free from grease

5. build-up, oil and dirt to prevent slippery conditions.

6. Perform all safety and maintenance checks before each period of use.

7. Replace parts with Stellar Industries, Inc. approved parts only.

8. Immediately repair or have repaired any components found to be inadequate.

Maintenance Procedures

1. Position the hooklift where it will be out of the way of other operations or vehicles in the area.

2. Place all controls in the off position and secure operating features from inadvertent motion.

3. Relieve hydraulic oil pressure from all hydraulic circuits before loosening or removing hydraulic components.

4. Label or tag parts when disassembling.

Periodic Inspection

Periodic Inspection should occur while the hooklift is in use. For the duration of the usage, inspect the hooklift for all of the following:

1. Loose bolts and fasteners.

2. All pins, bushings, shafts, and gears for wear, cracks, or distortion to include all pivot points, and bushings.

Hydraulic systems for pr

4. Main frame mount bolts.

5. Cylinders for:

A. Damaged rods. B. Dented barrels. C. Drift fr D. Leaks at rod seals or holding valves.

6. PTO and hydraulic pump(s) for leaks. Hydraulic hose and tubing for evidence of damage

7. such as blistering, crushing, or abrasion.

esence of this owner’s manual.

8. Pr

Daily Inspection

Daily Inspection should occur each day before the hooklift is put into use. Each day, inspect the hooklift for all of the following:

om oil leaking inter

oper operating pr

nally.

essur

1. Hydraulic oil level.

2. Loose parts or damage to structures or weld.

3. Cylinder movement due to leakage. 4

. Hoses for evidence of oil leaks.

5. Controls for malfunction or adjustment.

6. Parking brake operation.

7. All securing hardware such as cotter pins, snap rings, h

airpins, and pin keepers for proper installation.

8. All safety covers for proper installation.

9. Cylinder holding valves for proper operation.

10. Equipment for missing, illegible, or defaced operat-

ing decals and safety signs.

Monthly Inspection

Monthly Inspection should occur at the beginning of every work month. Each month, inspect the hooklift for all of the following:

1. Frame bolt tightness - turn barrel nuts and mounting

bolts during the first month of operation on new machines and then quarterly thereafter.

2. Cylinders and valves for leaks.

3. Lubrication.

4. Tilt hook for cracks.

5. Structural weldments for bends, cracks, or breaks.

6. All pins and keepers for proper installation.

7. All control, safety, and capacity placards for read-

ability and secure attachment.

8. Inspect all electrical wires and connections for worn,

cut, or deteriorated insulation and bare wire. Replace or repair wires as required.

10. Lubrication of all points requiring lubrication.

General Service

The following general suggestions should be helpful in analyzing and servicing your hooklift. Using the following systematic approach should be helpful in finding and fixing problems:

1. Deter

2. List and record possible causes.

3. Devise checks.

4. Conduct checks in a logical order to determine the

5. Consider the remaining service life of components

6. Make the necessary repair.

7. Recheck to ensur

8. Functionally test the new part in its system.

mine the pr

cause.

against the cost of parts and labor necessary to replace them.

oblem.

e that nothing has been overlooked.

Cleanliness

An important item in preserving the

long life of the hooklift is keeping dirt,

grime, and corrosive material out of the working parts. Thoroughly wash

and grease the hooklift periodically.

10 Flex36 Owner’s Manual

Choice Lubricants for DX Bearings

Type of Grease Description

Greases Recommended

Premium Quality Multi-Purpose

Multi-Purpose Calcium Based, for General Automotive and Industrial Use

Anti-Friction Bearing Calcium Based with EP Additives

Extreme Pressure (EP) Lithium Based with EP Additives

High Temperature Modified Sodium Based, High Drop Point Transmission Semi-Fluid, Calcium Based Molybdenum Filled Lithium Based with 2% Molybdenum Disulfide Graphite Filled Sodium Based with 2% Graphite Block Grease Sodium Based Solid Grease White Grease Aluminum Complex Based with Anti-Oxidant & Rust

Silicone Lithium Based with Silicone Oil Lubricant

Stabilized, Anti-Oxidant Lithium Base Lithium Base with 3% Molybdenum Disulfide High Drop Point

Calcium Grease, Water Stabilized, High Drop Point

Lithium Based Sodium Based

Calcium Based with EP Additives

Inhibitors & Zinc Oxide Additives

Greases Not Recommended

Type of Grease Description

Cup Grease Light Service Calcium or Sodium Based Grease Graphite Filled Greases with More than 10% Graphite

Molybdenum Filled Greases with More than 10% Molybdenum Disulfide Fluorocarbon Low Molecular Weight Chlorofluoroethylene Polymer

with Inert Thickeners

White Grease Calcium Based, Zinc Oxide Filled

Chapter 4 - Specifications

• Standard in-cab manual controls which allow for precise metering of the manual hydraulic valve. Solenoid-activated hydraulic control valve with electric remote control pendant is optional.

• Ten (10) gallon capacity frame-mounted oil reservoir.

• Hydraulic flow shall not exceed 16-gallons per minute.

• Patented dump/load interface on double pivot models.

• Hydraulic locks to prevent cylinder movement in case of pressure loss.

• Grease zerks at all points to allow purging of contaminates.

• Mechanical rear body tie-down latches.

• Resettable dump/tilt tabs.

11Specifications 11

• Hydraulic rotary valve to prevent front tilt movement when the dump frame is raised.

• DX pre-lubricated bushings used at pivot points.

• Greaseable load rollers.

60-8 84-10 108-12 120-14

Lifting/Dumping Capacity Up to 9,000lbs

(4,082kg) (7,257kg) (7,257kg) (7,257kg) A Dump Angle 54° 53° 54° 50° B Lowest Hook Heigh 23.5” (60cm) 25” (63.5cm) 27” (68.5cm) 28” (71cm)

fective Length

C D Truck Frame Height 34” (86cm) 36” (91.5cm) 36” (91.5cm) 36” (91.5cm) E Hooklift Height 39.5” (100cm) 41.5” (105.5cm) 41.5” (105.5cm) 41.5” (105.5cm)

Hooklift Length 99.25” (252cm) 126” (320cm) 154” (391cm) 161” (409cm)

G H Hooklift Center of Gravity 43” (109cm) 58” (147cm) 68” (173cm) 70” (178cm) I Chassis Cab to Axle 60” (152.5cm) 84”-96” 108”-120” 120”-130”

J Max. Height When Loading 104” (264cm) 118” (300cm) 135” (343cm) 136” (345.5cm) K Longest Body to Dump 120” (305cm) 144” (366cm) 180” (457cm) 192” (488cm) L Max. Height When Dumping 141” (358cm) 162” (411.5cm) 185” (470cm) 187” (475cm)

Operating Pressure See table 1.1 See table 1.1 See table 1.1 See table 1.1 Shipping Weight 1,275lbs (578.5kg) 1,360lbs (617kg) 1,615lbs (733kg) 1,650lbs (748.5kg) Hook Height (from bottom of hook bar) Shipping Dimensions 100”x49”x47” 126”x49”x47” 154”x49”x47” 161”x49”x47”

(LxHxW) (254x124.5x119.5cm) (320x124.5x119.5cm) (391x124.5x119.5cm) (409x124.5x119.5cm)

91” (231cm) 115” (292cm) 142” (361cm) 151” (383.5cm)

35.63” (90.5cm)

Up to 16,000lbs

(213.5cm-244cm)

35.63” (90.5cm)

Up to 16,000lbs Up to 16,000lbs

(274.5cm-305cm)

35.63” (90.5cm)

(305cm-330cm)

35.63” (90.5cm)

12 Flex36 Owner’s Manual

Stellar Flex36 Model 60-8 Hydraulic Hooklift Specifications

ifting Capacity: Check table 1.1 for variable lifting capabilities.

ontainer Length: 8-foot through 9-foot. Longer bodies up to 10-feet may be accommodated if full dump angle is not required (may require

pecial body-mounted or extendable truck-mounted bumper and additional latches to meet the Federal Motor Carrier

afety Administration (FMCSA) Rear End Protection regulation 393.86 and Securing Hooklift Containers regulation 393.134).

ody length does not include A-frame.

Maximum Dump Angle: 54°

Operating Pressure: See table 1.1 in Chapter 6: Installation for variable pressure settings.

Weight of Hooklift: Hooklift weight not to exceed 1,275 pounds.

Height of Hooklift: Hooklift height not to exceed 5.5" as measured from top of truck frame to top of hooklift rollers.

Hook Height: 35.63-inches from bottom of skid rails to bottom of hook bar. Hooklift must be able to pick up body

10-inches below grade, when mounted on a 34” truck frame height.

Hydraulic Pump: Direct-coupled high-pressure gear pump.

Hydraulic Contro

ontrols: D

Tilting Hook Assembly: Hooklift must have pivoting type front tilt section (jib) to provide a low degree loading/unloading angle and also to provide

Tilt Cylinder: Cylinder must be double acting (4” Bore x 2” Rod x 17” Stroke) and include dual integral pilot-operated counterbalance

Tilt Section Operation: Hooklift must include a hydraulic lock-out device to prevent operation of the tilt section while hooklift is in the dumping

Lift/Dump Cylinder: Cylinder must be double acting and include dual pilot-operated counterbalance valves to prevent cylinder movement in

Dump/Tilt Interlock: Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock into a rigid full length 25” wide frame to

Rear Body Hold-downs: Dual fixed-position hold down devices mounted to the dump frame to secure the body to the hooklift through all ranges of

Rear Dump Hinge Pin: 2-inch diameter type 304 or 17-4 stainless steel minimum.

l Valve: Hydraulic valve mounted directly onto the oil reservoir with power beyond capabilities.

ual manual levers with sealed cable actuators mounted in the truck cab to allow full feathering of all hooklift functions.

a wider stance for side to side stability.

valves to prevent cylinder collapse in case of hose failure. Cylinder must be fully retracted when in the transport mode to

prevent exposure of cylinder rod to corrosive road salts.

mode.

case of pressure loss.

provide support for the container while in the dump mode. These sections form this frame without the use of mechanical

latches which rely on gravity, springs, or container/body mounted latches. The system must be protected from out of

sequence operation.

the dump mode. This must be accomplished without the use of steel springs and/or hydraulic/air cylinders.

Pins:

Bushings:

Hoses & Hyd. Fittings: All hoses and fittings are to be SAE; metrics are not to be allowed. O-ring face seal fittings to be utilized wherever possible.

Electrical: All electrical wiring to be protected by full length steel conduit fastened into the hooklift framework.

Technical Documentation: All hooklifts shall come with documentation on operation, maintenance, safety and a parts manual.

Regulations: Hooklift shall be designed and manufactured to all local, state and federal regulations.

Origin of Manufacture: Hooklift to be designed and manufactured in the United States of America.

All pins to be type 304 or 17-4 stainless steel.

All bushings to be of the DX pr

in heavy containment and corrosive environments.

ed steel hydraulic tubing to be used whenever possible.

Secur

e-lubricated variety, used with grease fittings. Bronze bushings not allowed due to survivability

Specifications 13

Stellar Flex36 Model 84-10 Hydraulic Hooklift Specifications

ifting Capacity: Check table 1.1 for variable lifting capabilities.

ontainer Length: 10-foot through 12-foot. Longer bodies up to 13-feet may be accommodated if full dump angle is not required (may require

pecial body-mounted or extendable truck-mounted bumper and additional latches to meet the Federal Motor Carrier Safety

dministration (FMCSA) Rear End Protection regulation 393.86 and Securing Hooklift Containers regulation 393.134). Body

ength does not include A-frame.

Maximum Dump Angle: 53°

Operating Pressure: See table 1.1 in Chapter 6: Installation for variable pressure settings.

Weight of Hooklift: Hooklift weight not to exceed 1,360 pounds.

Height of Hooklift: Hooklift height not to exceed 5.5" as measured from top of truck frame to top of hooklift rollers.

Hook Height: 35.63-inches from bottom of skid rails to bottom of hook bar. Hooklift must be able to pick up body

10-inches below grade, when mounted on a 36” truck frame height.

Hydraulic Pump: Direct-coupled high-pressure gear pump.

Hydraulic Contro

ontrols: D

Tilting Hook Assembly: Hooklift must have pivoting type front tilt section (jib) to provide a low degree loading/unloading angle and also to provide a

Tilt Cylinder: Cylinder must be double acting (4” Bore x 2” Rod x 17” Stroke) and include dual integral pilot-operated counterbalance

Tilt Section Operation: Hooklift must include a hydraulic lock-out device to prevent operation of the tilt section while hooklift is in the dumping mode.

Lift/Dump Cylinder: Cylinder must be double acting and include dual pilot-operated counterbalance valves to prevent cylinder movement in

Dump/Tilt Interlock: Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock into a rigid full length 25” wide frame to

Rear Body Hold-downs: Dual fixed-position hold down devices mounted to the dump frame to secure the body to the hooklift through all ranges of

Rear Dump Hinge Pin: 2-inch diameter type 304 or 17-4 stainless steel minimum.

Pins: All pins to be type 304 or 17-4 stainless steel.

l Valve: Hydraulic valve mounted directly onto the oil reservoir with power beyond capabilities.

ual manual levers with sealed cable actuators mounted in the truck cab to allow full feathering of all hooklift functions.

wider stance for side to side stability.

valves to prevent cylinder collapse in case of hose failure. Cylinder must be fully retracted when in the transport mode to pre-

vent exposure of cylinder rod to corrosive road salts.

case of pressure loss.

provide support for the container while in the dump mode. These sections form this frame without the use of mechanical

latches which rely on gravity, springs, or container/body mounted latches. The system must be protected from out of

sequence operation.

the dump mode. This must be accomplished without the use of steel springs and/or hydraulic/air cylinders.

Bushings: All bushings to be of the DX pre-lubricated variety, used with grease fittings. Bronze bushings not allowed due to survivability in

heavy containment and corr

Hoses & Hyd. Fittings: All hoses and fittings are to be SAE; metrics are not to be allowed. O-ring face seal fittings to be utilized wherever possible.

Secured steel hydraulic tubing to be used whenever possible.

Electrical:

Technical Documentation: All hooklifts shall come with documentation on operation, maintenance, safety and a parts manual.

Regulations:

Origin of Manufacture: Hooklift to be designed and manufactured in the United States of America.

All electrical wiring to be protected by full length steel conduit fastened into the hooklift framework.

Hooklift shall be designed and manufactured to all local, state and federal regulations.

osive envir

onments.

14 Flex36 Owner’s Manual

Stellar Flex36 Model 108-12 Hydraulic Hooklift Specifications

ifting Capacity: Check table 1.1 for variable lifting capabilities.

ontainer Length: 12-foot through 14-foot. Longer bodies up to 16-feet may be accommodated if full dump angle is not required (may require

pecial body-mounted or extendable truck-mounted bumper and additional latches to meet the Federal Motor Carrier Safety

dministration (FMCSA) Rear End Protection regulation 393.86 and Securing Hooklift Containers regulation 393.134). Body

ength does not include A-frame.

Maximum Dump Angle: 54°

Operating Pressure: See table 1.1 in Chapter 6: Installation for variable pressure settings.

Weight of Hooklift: Hooklift weight not to exceed 1,615 pounds.

Height of Hooklift: Hooklift height not to exceed 5.5" as measured from top of truck frame to top of hooklift rollers.

Hook Height: 35.63-inches from bottom of skid rails to bottom of hook bar. Hooklift must be able to pick up body

10-inches below grade, when mounted on a 36” truck frame height.

Hydraulic Pump: Direct-coupled high-pressure gear pump.

Hydraulic Contro

ontrols: D

Tilting Hook Assembly: Hooklift must have pivoting type front tilt section (jib) to provide a low degree loading/unloading angle and also to provide a

Tilt Cylinder: Cylinder must be double acting (4” Bore x 2” Rod x 17” Stroke) and include dual integral pilot-operated counterbalance

Tilt Section Operation: Hooklift must include a hydraulic lock-out device to prevent operation of the tilt section while hooklift is in the dumping mode.

Lift/Dump Cylinder: Cylinder must be double acting and include dual pilot-operated counterbalance valves to prevent cylinder movement in

Dump/Tilt Interlock: Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock into a rigid full length 25” wide frame to

Rear Body Hold-downs: Dual fixed-position hold down devices mounted to the dump frame to secure the body to the hooklift through all ranges of

Rear Dump Hinge Pin: 2-inch diameter type 304 or 17-4 stainless steel minimum.

Pins: All pins to be type 304 or 17-4 stainless steel.

l Valve: Hydraulic valve mounted directly onto the oil reservoir with power beyond capabilities.

ual manual levers with sealed cable actuators mounted in the truck cab to allow full feathering of all hooklift functions.

wider stance for side to side stability.

valves to prevent cylinder collapse in case of hose failure. Cylinder must be fully retracted when in the transport mode to pre-

vent exposure of cylinder rod to corrosive road salts.

case of pressure loss.

provide support for the container while in the dump mode. These sections form this frame without the use of mechanical

latches which rely on gravity, springs, or container/body mounted latches. The system must be protected from out of

sequence operation.

the dump mode. This must be accomplished without the use of steel springs and/or hydraulic/air cylinders.

Bushings: All bushings to be of the DX pre-lubricated variety, used with grease fittings. Bronze bushings not allowed due to survivability in

heavy containment and corr

Hoses & Hyd. Fittings: All hoses and fittings are to be SAE; metrics are not to be allowed. O-ring face seal fittings to be utilized wherever possible.

Secured steel hydraulic tubing to be used whenever possible.

Electrical:

Technical Documentation: All hooklifts shall come with documentation on operation, maintenance, safety and a parts manual.

Regulations:

Origin of Manufacture: Hooklift to be designed and manufactured in the United States of America.

All electrical wiring to be protected by full length steel conduit fastened into the hooklift framework.

Hooklift shall be designed and manufactured to all local, state and federal regulations.

osive envir

onments.

Specifications 15

Stellar Flex36 Model 120-14 Hydraulic Hooklift Specifications

ifting Capacity: Check table 1.1 for variable lifting capabilities.

ontainer Length: 13-foot through 15-foot. Longer bodies up to 16-feet may be accommodated if full dump angle is not required (may require

pecial body-mounted or extendable truck-mounted bumper and additional latches to meet the Federal Motor Carrier Safety

dministration (FMCSA) Rear End Protection regulation 393.86 and Securing Hooklift Containers regulation 393.134). Body

ength does not include A-frame.

Maximum Dump Angle: 50°

Operating Pressure: See table 1.1 in Chapter 6: Installation for variable pressure settings.

Weight of Hooklift: Hooklift weight not to exceed 1,650 pounds.

Height of Hooklift: Hooklift height not to exceed 5.5" as measured from top of truck frame to top of hooklift rollers.

Hook Height: 35.63-inches from bottom of skid rails to bottom of hook bar. Hooklift must be able to pick up body

10-inches below grade, when mounted on a 36” truck frame height.

Hydraulic Pump: Direct-coupled high-pressure gear pump.

Hydraulic Contro

ontrols: D

Tilting Hook Assembly: Hooklift must have pivoting type front tilt section (jib) to provide a low degree loading/unloading angle and also to provide a

Tilt Cylinder: Cylinder must be double acting (4” Bore x 2” Rod x 17” Stroke) and include dual integral pilot-operated counterbalance

Tilt Section Operation: Hooklift must include a hydraulic lock-out device to prevent operation of the tilt section while hooklift is in the dumping mode.

Lift/Dump Cylinder: Cylinder must be double acting and include dual pilot-operated counterbalance valves to prevent cylinder movement in

Dump/Tilt Interlock: Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock into a rigid full length 25” wide frame to

Rear Body Hold-downs: Dual fixed-position hold down devices mounted to the dump frame to secure the body to the hooklift through all ranges of

Rear Dump Hinge Pin: 2-inch diameter type 304 or 17-4 stainless steel minimum.

Pins: All pins to be type 304 or 17-4 stainless steel.

l Valve: Hydraulic valve mounted directly onto the oil reservoir with power beyond capabilities.

ual manual levers with sealed cable actuators mounted in the truck cab to allow full feathering of all hooklift functions.

wider stance for side to side stability.

valves to prevent cylinder collapse in case of hose failure. Cylinder must be fully retracted when in the transport mode to pre-

vent exposure of cylinder rod to corrosive road salts.

case of pressure loss.

provide support for the container while in the dump mode. These sections form this frame without the use of mechanical

latches which rely on gravity, springs, or container/body mounted latches. The system must be protected from out of

sequence operation.

the dump mode. This must be accomplished without the use of steel springs and/or hydraulic/air cylinders.

Bushings: All bushings to be of the DX pre-lubricated variety, used with grease fittings. Bronze bushings not allowed due to survivability in

heavy containment and corr

Hoses & Hyd. Fittings: All hoses and fittings are to be SAE; metrics are not to be allowed. O-ring face seal fittings to be utilized wherever possible.

Secured steel hydraulic tubing to be used whenever possible.

Electrical:

Technical Documentation: All hooklifts shall come with documentation on operation, maintenance, safety and a parts manual.

Regulations:

Origin of Manufacture: Hooklift to be designed and manufactured in the United States of America.

All electrical wiring to be protected by full length steel conduit fastened into the hooklift framework.

Hooklift shall be designed and manufactured to all local, state and federal regulations.

osive envir

onments.

16 Flex36 Owner’s Manual

Chapter 5 - Decals

Decals of Note

17Decals 17

Electrocution Hazard Decal

Location: On each side of the tilt base. Function: To inform the operator of the hazard

associated with electrocution, the possible consequences should the hazard occur, and how to avoid the hazard. PN: C1179

Hands Clear Decal

Location: On each side of the tilt base. Function: To inform the operator of the

hazard associated with tilt operation, the possible consequences should the haz-

ard occur, and how to avoid the hazard PN: C0865

Operation Hazard Decal

Location: Truck Frame Function: To inform the operator of the

need for proper training, familiarity with safe operating pr possible consequences without training. PN: C4540

ocedures and , the

Operation Hazard Decal

Location: Truck Frame Function: To inform the operator and other

personnel in the work area of the hazard associated with improper maintenance and unauthorized modifications, the possible consequences should the hazard occur, and how to avoid the hazard. PN: 4190

18 Flex36 Owner’s Manual

PN 35559

Decal Kit Placement - PN 35559

Installation

Chapter 6 - Installation

Every hooklift installation is unique. However, certain guidelines exist that apply to every model. Listed below is a general set of chronological steps that may be followed when installing a Stellar Hooklift. If any questions arise during the installation process, feel free to contact your local dealer or Stellar Customer Service at 800-321-3741.

Chapter Contents

Basic Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Installation Steps - Basic Guidelines . . . . . . . . . . . . . . . . . . . . . . . .20

Mounting Kit (Model 60-8) - PN 33320 . . . . . . . . . . . . . . . . . . . . . .22

Mounting Kit (Models 84-10, 108-12, 120-14) - PN 23700 . . . . . . .23

Rotary Valve (All Models) - PN 37741 . . . . . . . . . . . . . . . . . . . . . . .24

Reservoir Assembly - PN 35883 . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Setting System Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . .26-27

Installation Instructions for the Power Beyond VDM8 Valve . . . .28

Port Side Relief Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Controller Assembly - PN 38841 . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Dump Light Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Hydraulic Schematic (Model 60-8) - PN 34616

Hydraulic Schematic (Model 84-10)- PN 34617 . . . . . . . . . . . . . .33

Hydraulic Schematic (Model 108-12) - PN 34618 . . . . . . . . . . . . .34

Hydraulic Schematic (Model 120-14)- PN 34619 . . . . . . . . . . . . .35

Subframe Model 60-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Subframe Model 84-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Subframe Model 108-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Subframe Model 120-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

. . . . . . . . . . . . . . .32

Basic Installation Overview

1. Clear the truck frame.

2. Set the Flex on the truck frame.

3. Shorten the truck frame to within 2” from the rear of the loader.

4. Install bumper.

5. Install tie down channels. (See corresponding Mounting Kit Drawing in this chapter)

6. Install tarper tower (If applicable).

7. Install cab and PTO controls.

8. Mount hydraulic reservoir tank and valve bank.

9. Mount PTO and Pump.

10. Run hydraulic hoses.

11. Connect suction and pressure to the reservoir tank and valve bank.

12. Install mud flaps and fenders.

13. Run Flex.

20 Flex36 Owner’s Manual

Installation Steps - Basic Guidelines

1. Clear the truck frame.

2. Set the Flex on the truck frame.

a. The front plate of the base needs to be at least 2” behind the cab or any equip-

ment mounted behind the cab. b. Be sure to square the Flex on the truck frame. c. Take a visual and look for any potential issues. For example: Clearance problems,

cross members extending too high, insufficient room in front of the Flex for tarpers,

exhaust manifolds, etc, or insufficient room in the rear to allow for bumper selec-

tion. Feel free to space up if needed.

3. Shorten the truck frame to within 2” from the rear of the loader.

4. Install bumper.

a. See Government Regulations for acceptable placement.

5. Install tie down channels. (See corresponding Mounting Kit Drawing in this chapter)

a. Move anything on the truck frame that may be in the way of the tie down chan-

nels. b. Place a tie down channel on either side of the base, within 2” of the front plate. c. Place a tie down channel on either side of the base, within 7” of the rear of the

hooklift.

d. The final channels should be placed in the approximate position shown in the cor-

responding mounting diagram. The top of the lower channel should be flush with

the top of the chassis frame rail. e. Using the channels as a guide, drill six (6) 11/16” holes through the truck frame.

(Note: For Flex36 Model 60-8, you only need to drill four (4) holes.) f. Using 5/8” bolts, washers, and nuts, secure all tie down channels to the truck

frame. All bolts should be torqued to 160 ft-lbs.

h. Weld the upper tie down channels to the hooklift base. Use 5/8” washers to

space the channels up. Remove washers when finished.

g. Using 5/8” bolts, washers, and nuts, fasten two (2) tie-down channels together with

the narrow faces toward each other. Do this with all of the channels.

6. Install tarper tower (If applicable).

a. See brand specific installation instructions.

7. Install cab and PTO controls.

a. Use PTO brand specific installation instructions. b. See Controller Assembly Drawing (PN 38841) for details. c. See Dump Light Kit Installation

8. Mount hydraulic reservoir tank and valve bank.

a. Make sure the tank isn’t too far away if cables are being used. b. Don’t raise the tank above the frame height. c. See Power Beyond Installation guide for valve bank details. d. See Reservoir Assembly Drawing PN 35883 for details.

9. Mount PTO and Pump.

a. Be sure to check the rotation of the pump to ensure proper installation. b. Use brand specific installation instructions.

Installation 21

10. Run hydraulic hoses.

a. Run hoses between the pump and reservoir tank. b. Run hoses between the PTO and valve bank. c. Protect these lines with hose wrap when necessary. d. Keep these lines away from sharp edges. e. Keep these lines away from the exhaust or other temperature extreme items. f. Keep these lines away from the driveshaft or other moving items. g. See hydraulic schematics for details.

11. Connect suction and pressure to the reservoir tank and valve bank.

a. Fittings on the valve bank should be 3” lower than the long sills. b. Fill reservoir to site gauge, within 3” from the top (Roughly 10 Gallons). c. Petro-Canada Hydrex 32 (ISO 32) hydraulic oil is recommended. d. When connections are secure, turn reservoir on.

12. Install mud flaps and fenders.

3. Run Flex.

a. Bleed the air out of the hydraulic system. b. Check the oil level and add oil if needed. c. Calibrate rotary valve. d. Calibrate dump light system. e. Be sure to check all clearances. f. Set/check relief pressure no higher than 4200 PSI (see chart/diagram).

22 Flex36 Owner’s Manual

PN 33320

ITEM PART DESCRIPTION QTY. 1D0143 TIE DOW N CHANNEL 8 2C1025 CAP SCR 0.63-11X2.00 HHGR8 ZY 8 3C1038 WASHER 0.63 FLAT 16 424868 NUT 0.63-11 HH NYLOC 8 5D0045 BACKUP ALARM .97 DECIBAL 1

Mounting Kit (Model 60-8) - PN 33320

Installation 23

.YT

OITPIRC

21LEN

WOD EIT

341

21YZ 8RGHH 00.2X11-36.0 RCS P

201

42TALF 36.0 REHSA

8301C3

21COLYN HH 11-36.0 TU

868424

1LABIC

ED 79

. MR

ALA

PUKC

AB5

400D5

PN 23700

Mounting Kit (Models 84-10, 108-12, 120-14) - PN 23700

24 Flex36 Owner’s Manual

YTQNOITPIRCSEDTR

APMETI

1MSA EVLAV YRATOR654221 2 22450 WLDMT ROTARY VALVE ECCENTRIC 1 3D1638 O'RING 1.12X1.38X0.12 568-216 1 4 3748 WASHER ROTARY VALVE 1 5 0480 CAP SCR 0.25-20X1.00 HHGR5 1 6 0353 CAP SCR 0.38-16X2.00 HHGR5 3 7 0347 NUT 0.38-16 HH NYLOC 3 8 0977 O'RING 1.00X1.25X0.12 568-214 1 9 22449 PLATE ROTARY VALVE ARM 1

10 0482 CAP SCR 0.25-20 X 3.00 HHGR5 2 11 0333 NUT 0.25-20 HHGR5 NYLOC 2 12 7350 FTG ST RUN TEE 8R5OLO 2 13 D1535 PLUG STR HOLLOW HEX 0.50 8-HP5ON 2

37741

Rotary Valve (All Models) - PN 37741

To adjust rotary valve move hooklift into stowed position. Loosen the bolts that are attaching the valve block to the dump section. Adjust rotary arm so that it is in contact with the dump plate. Push the rotary arm up as you pull the valve block back towards the rear of the loader. Tighten valve block bolts while making sure valve block is snug. Note: It should engage between 4 and 10 degrees.

.YTQNOITPIRCSEDTRAP

1 26455 RSRVR ASM 10GAL K MODEL 1 2 1115 FTG NIPPLE HEX MALE 010 1-20-20 1 3 c2242 ST EL 0.75 90 DEG BLK 2 4 3320 NIPPLE 0.75X12.00 PIPE 1

AEH RE

TLIF6226c5 6 C6229 FILTER LARGE AE-10L 1 7 C6014 FTG ADAPT 8-12 FOLO-S 1

2.1 LLAB

VLA

1155C8

9 C2282 FTG 1.25 NPT TO 1.25 BARB 1

10 24611 VB 2-SECTION VDM8 1

3KCOL 52.0 RE

HSAW1

25011

12 0339 CAP SCR 0.25-20X2.50 HHGR5 3

.YTQNOITPIRCSE

TRA

PMETI 13 C4227 FTG MF/MSTR 90 8-12 C5OLO-S 1 14 26731 HOSE 0.50(381-JC-J9-8-8-8-18-0) 1 15 0352 WASHER 0.50 USS FLAT ZINC 8 16 C6106 NUT 0.50-13 HHGR5 NYLOC 4 17 0506 CAP SCR 0.50-13X4.00 HHGR5 4 18 D0549 FTG ADAPT 16-8 F5OG5-S 1 19 17767 HOSE SUCT 1.25 10FT 1 20 C1123 HOSE CLAMP 88 DB-20 2 21 C4747 NIPPLE O'RING 45 4603-20-16 1 22 10094 GAUGE OIL LF 2.5" 0-500 BM 1 23 9892 SPACER TANK MOUNTING 10 GAL 2 24 16145 GAUGE PRES FILTER SERVICE CI20 1

.YTQNOITPIRCSE

RAPMETI 25 25630 FTG ADAPT 10-1/4 F5OG 1 26 C2252 FTG ADAPT 8-10-F5OLO-S 5 27 C2376 FTG ADAPT 8-C6LO-S 1 28 31676 HOSE 0.50(471TC-JC-JC-8-8-8-120) 1 29 1554 FTG ADAPT 8-F5OLO-S 1

PN 35883

Reservoir Assembly - PN 35883

Installation 25

26 Flex36 Owner’s Manual

4500

5500

6500

7500

8500

9500

10500

11500

12500

13500

14500

15500

2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000 4200 4400

SYSTEM RELIEF PRESSURE (P.S.I.)

LOADER CAP

ACITY (POUNDS)

60 CA 84 CA 108 CA 120 CA

Pressure vs. Capacity

60 CA 84 CA 108 CA 120 CA

Setting System Relief Pressure

Table 1.1*

Instruction Overview:

See next page for details.

1. Engage the PTO. Run truck at 1300 RPM.

2. Push the red (lift) lever until the boom bottoms out. Keep pushing the lever forward until the pressure is set.

Never Exceed the

Maximum

Pressure of 4200 psi.

Never adjust System Relief Pressure to allow Loader

Capacity to exceed chassis GVW and always per-

form a weight distribution before installation and

after System Relief Pressure adjustments to confirm

Loader Capacity and chassis compatibility.

3. Release the jam nut using a 13 mm wrench.

4. Adjust the system r

elief pressure

using 4 mm allen wrench.

5. Once system pressure is set, tighten the jam nut to lock system pressure. No per lock may be used

manent thread

Setting System Relief Pressure Continued

27Installation 27

1. Engage the PTO. Run the truck at 1300 RPM.

3. Release the jam nut using a 13 mm wrench.

2. Push the red (lift) lever until the boom bottoms out. Keep pushing the lever forward until steps 3-5 are complete.

4. Adjust the system relief pressure using 4 mm allen wrench. Clockwise increases pressure, counter clockwise decreases pressure.

5. Once system pressure is set, tighten the jam nut to e. Permanent thread lock should

lock system pr not be used.

essur

6. Release all functions and disengage the PTO. Snap tamper cap into position over the jam nut. The br away clip will be destroyed if the cap is removed.

eak

28 Flex36 Owner’s Manual

Installation Instructions for the Power Beyond VDM8 Valve

These instructions ar intended for correct installation of power beyond on a Salami VDM8 valve bank. If any hydraulic component is integrated after this valve the power beyond must be installed correctly, or serious damage may incur to the hydraulic system.

1. Remove cover/access plug to reveal the power

beyond access point. Can also be used as the Return/Tank port.

3. The Power Beyond feature is now activated and will

divert oil to alternate system via the port shown.

2. Install a 3/8” straight thread pipe plug into lower portion of cavity to activate the power beyond feature. Use thread sealer (tape sealers not recommended.

Note:

1. The return/tank line must be connected to the top or the side port, labeled “T”.

2. Using the return line to run auxiliary equipment will directly result in a failure and will not in any circumstance be covered under warranty.

3. A standard Stellar hooklift will have 6 hydraulic lines attached to the valve. A Stellar hooklift with Power Beyond will have 7 hydraulic lines attached to the valve.

MAIN CYLINDER RETRACT PORT

PLUG

PORT SIDE RELIEF

MAIN RELIEF

VALVE BANK

• For some options, port side relief is required.

• To install port side relief:

1. Remove plug.

2. Insert relief.

3. Replace plug

• Relief can be installed on the retract or extend side of the valve bank.

Port Side Relief Installation

Installation 29

30 Flex36 Owner’s Manual

CONTROLLER CABLES TO VALVE BANK

.YTQNOITPIRCSEDTRAPMETI 137474 CONTROLLER CTR LOCK RIGHT BEND 1 237475 CONTROLLER CTR LOCK LEFT BEND 1

1TNM MRALA BAT ETALP392623 437470 VALVE CTRL CONSOLE 2LEVER RVC 1 50491 CAP SCR 0.31-18X4.00 HHGR5 2 60343WASHER 0.31 USS FLAT ZINC 4

2COLYN HH 81-13.0 TUN24307 826031 BACKUP ALARM PIEZO JAMECO 123537 1 926135 DECAL NOTICE FIX TABS 1

10 D1711 CAP SCR #10-24X0.50 BTNHD SS 1 11 C6072 RELAY BOSCH 20-30 AMP 1 12 26288 LIGHT INDICATOR RED FORCE PTO 1 13 31806 DUMP UP LIGHT KIT BUYERS SK10 1 15 25933 BRKT CONTROLLER DECAL 1

1 COLYN HH 42-01# TUN4306261

18 37469 CABLE CONN. KIT FOR VD8A/VDM8 2

28MDV TCES-2 BV1164291

20 26291 WIRE HARNESS TAB ALARM 1 21 26289 WIRE HARNESS PROXIMITY SWITCH 1 17 37471 CONTROL CABLE 96" WESCON 2

NOTE: CONTROL LEVER, HA NDLES, CONSOLE, AND CONTROLLER CABLES ARE INCLUDED WITH THE HYDRA ULIC CONTROL VAL VE.

PN 38841

Controller Assembly - PN 38841

• Bolt L-bracket to front of base, drilling and tapping holes in appropriate area.

• Attach dump light switch to L-bracket.

• Drill and tap ¼-20 hole in bottom of secondary tube. Hole should be located directly above dump light switch when secondary is in lowered position.

• Screw in elevator bolt, and adjust so that switch is engaged when secondary is in lowered position.

• Install light in bracket provided with control console.

• Complete the wiring; following instructions provided with dump light kit.

Elevator bolt

L-bracket

Dump light switch

Detail A Scale 1 : 8

Dump Light Kit Installation

31Installation 31

32 Flex36 Owner’s Manual

ALVE

OTARY

ETRACT

EXTEND

MAIN

ETRACT

XTEND

ILT

HOSE .38 X 91.00

OSE .50 X 60.00

OSE .38 X 41.00

OSE ASM 9-16M LOADERS

HOSE .38 X 60.00

PART No.ITEM

34646

34644

8169

4645

464701

QTY

DESCRIPTION

2ref

ref

0.00

STELLAR #34644- (471TC-J0-J9-8-8-6-60")

0562(HOSE-.38)

4651

6392

QTY - 2

FUNCTION: TILT VB TO PORT TUBES

C2773(HOSE-.50)

STELLAR #18169 - (471TC-JC-J9-8-8-8-60")

0.00

FUNCTION: MAIN CYLINDER

1558

QTY - 2

C1559

C0562(HOSE-.38)

91.00

STELLAR #34646 - (471TC-JC-J9-8-6-6-91")

FUNCTION: TILT ROTARY VAVLVE TO CYLINDER

6391

QTY -2

0546

STELLAR #34645 - (471TC-JC-J0-8-8-6-41")

1.00

C0562(HOSE-.38)

4651

FUNCTION: PORT TUBES TO ROTARY VALVE

QTY - 2

6391

ILT RETRACT

MAIN RETRACT

PRESSURE FROM PUMP

ILT EXTEND

MAIN EXTEND

NOTE: IF RESERVOIR IS MOUNTED ON CS HOSES 3 AND 4 ARE REVERSED

RETURN TO TANK

PN 34616

Hydraulic Schematic (Model 60-8) - PN 34616

ALVE

OTARY

ETRACT

EXTEND

AIN

RETRACT

XTEND

ILT

HOSE .38 X 115.00

HOSE .50 X 60.00

HOSE .38 X 41.00

OSE ASM 9-16M LOADERS

OSE .38 X 60.00

PART No.ITEM

34648

4644

18169

34645

464701

QTY

ESCRIPTION

ref

2ref

0.00

STELLAR #34644- (471TC-J0-J9-8-8-6-60")

0562(HOSE-.38)

34651

6392

QTY - 2

FUNCTION: TILT VB TO PORT TUBES

C2773(HOSE-.50)

STELLAR #18169 - (471TC-JC-J9-8-8-8-60")

0.00

FUNCTION: MAIN CYLINDER

1558

QTY - 2

1559

C0562(HOSE-.38)

115.00

STELLAR #34648 - (471TC-JC-J9-8-6-6-115")

FUNCTION: TILT ROTARY VAVLVE TO CYLINDER

391

QTY -2

546

STELLAR #34645 - (471TC-J0-JC-8-8-6-41")

41.00

C0562(HOSE-.38)

4651

FUNCTION: PORT TUBES TO ROTA RY VALVE

QTY - 2

6391

ILT RETRACT

MAIN RETRACT

PRESSURE FROM PUMP

TILT EXTEND

AIN EXTEND

NOTE: IF RESERVOIR IS MOUNTED ON CS HOSES 3 AND 4 ARE REVERSED

RETURN TO TANK

PN 34617

Hydraulic Schematic (Model 84-10)- PN 34617

33Installation 33

34 Flex36 Owner’s Manual

VALVE

OTARY

RETRACT

EXTEND

AIN

ETRACT

EXTEND

TILT

HOSE .38 X 145.00

HOSE .50 X 60.00

HOSE .38 X 41.00

OSE ASM 9-16M LOADERS

HOSE .38 X 60.00

ART No.ITEM

34649

34644

18169

34645

464701

DESCRIPTION

2ref

60.00

STELLAR #34644- (471TC-J0-J9-8-8-6-60")

C0562(HOSE-.38)

4651

392

QTY - 2

FUNCTION: TILT VB TO PORT TUBES

C2773(HOSE-.50)

TELLAR #18169 - (HTB-JC-J9-8-8-8-60")

60.00

FUNCTION: MAIN CYLINDER

C1558

QTY - 2

1559

0562(HOSE-.38)

45.00

STELLAR #34649 - (471TC-JC-J9-8-6-6-145")

FUNCTION: TILT ROTARY VAVLVE TO CYLINDER

6391

QTY -2

0546

STELLAR #34645 - (471TC-JC-J0-8-8-6-41")

41.00

C0562(HOSE-.38)

34651

FUNCTION: PORT TUBES TO ROTA RY VALVE

QTY - 2

6391

ILT RETRACT

MAIN RETRACT

PRESSURE FROM PUMP

ILT EXTEND

MAIN EXTEND

NOTE: IF RESERVOIR IS MOUNTED ON CS HOSES 3 AND 4 ARE REVERSED

RETURN TO TANK

PN 34618

Hydraulic Schematic (Model 108-12) - PN 34618

Installation 35

VALVE

ROTARY

RETRACT

XTEND

AIN

RETRACT

EXTEND

TILT

HOSE .38 X 150.00

OSE .50 X 60.00

HOSE .38 X 41.00

OSE ASM 9-16M LOADERS

OSE .38 X 60.00

PART No.ITEM

34650

4644

8169

34645

464701

QTY

ESCRIPTION

ref

2ref

0.00

STELLAR #34644- (471TC-J0-J9-8-8-6-60")

0562(HOSE-.38)

4651

6392

QTY - 2

FUNCTION: TILT VB TO PORT TUBES

2773(HOSE-.50)

STELLAR #18169 - (471TC-JC-J9-8-8-8-60")

0.00

FUNCTION: MAIN CYLINDER

1558

QTY - 2

C1559

C0562(HOSE-.38)

150.00

STELLAR #34650 - (471TC-JC-J9-8-6-6-150")

FUNCTION: TILT ROTARY VAVLVE TO CYLINDER

391

QTY -2

546

STELLAR #34645 - (471TC-JC-J0-8-8-6-41")

1.00

0562(HOSE-.38)

34651

FUNCTION: PORT TUBES TO ROTA RY VALVE

QTY - 2

6391

TILT RETRACT

MAIN RETRACT

PRESSURE FROM PUMP

TILT EXTEND

MAIN EXTEND

RETURN TO TANK

PN 34619

Hydraulic Schematic (Model 120-14)- PN 34619

36 Flex36 Owner’s Manual

(multi-lift only)

Subframe Model 60-8

Subframe Model 84-10

Installation 37

38 Flex36 Owner’s Manual

Subframe Model 108-12

Subframe Model 120-14

Installation 39

40 Flex36 Owner’s Manual

Chapter 7 - Assembly Drawings

PN 31823

ITEM PART DESCRIPTION QTY. ITEM PART DESCRIPTION QTY. 1 31815 BASE WLDMT 60- 8 FLEX36 1 12 C0953 CAP SCR 0.38-16X4.00 HHGR5 4 2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4 13 0347 NUT 0.38-16 HH NYLOC 4 3 19291 ROLLER 4" OD 2 14 c1592 ZERK 1/8 NPT STRAIGHT 2 4 1546 THRUST W ASHER 2.01DIA UHMW .12THK 6 15 C0078 HOSE CLAMP #8 RU BBER COATED 1 5 8819 BUSHING QSI-3235-16 2 16 0479 CAP SCR 0.25-20X0.75 HHGR5 1 6 24766 PIN 2.00X47.00 1 17 0333 NUT 0.25-20 HHGR5 NYLOC 1 7 23699 BUSHING 32DXR20 2.00X1.25 2 18 8622 CLAMP HO SE/TUBE AG-2 8 8 33741 PIN 2.00X10.19 SR 1 19 34415 TUBE ASM 0.50X65.25 2 9 0427 MACHY WASHER 2.00ID 10GA 2 20 0220 CAP SCR 0.25-20 X 1.50 HHGR5 4 10 0108 SNAP RING 2.00 7200-200 2 21 0340 WASHER 0.25 FLAT 4 11 22764 COLLAR 2.01X3.00X1.00 4 22 34622 PLUG PLASTIC 1.25X0.19 CCF1.5-14-20 4

Base Assembly (60-8) - PN 31823

41Assembly Drawings 41

42 Flex36 Owner’s Manual

PN 33337

ITEM PART DESCRIPTION QTY. ITEM PART DESCRIPTION QTY. 1 33338 BASE WLDMT 84-10 FLEX36 1 12 c1592 ZERK 1/8 NPT STRAIGHT 2 2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4 13 C0078 HOSE CLAMP #8 RUBBER COATED 1 3 19291 ROLLER 4" OD 2 14 0479 CAP SCR 0.25-20X0.75 HHGR5 1 4 1546 THRUST W ASHER 2.01DIA UHMW .12THK 6 15 0333 NUT 0.25-20 HHGR5 NYLOC 1 5 8819 BUSHING QSI-3235-16 2 16 0427 MACHY WASHER 2.00ID 10GA 2 6 24766 PIN 2.00X47.00 1 17 0108 SNAP RING 2.00 7200-200 2 723699 BUSHING 32DXR20 2.00X1.25 2 18 8622 CLAMP HOSE/TUBE AG-2 10 8 34411 PIN 2.00X10.31 SR 1 19 34418 TUBE ASM 0.50X95.00 2 9 22764 COLLAR 2.01X3.00X1.00 4 20 0340 WASHER 0.25 FLAT 5 10 0532 CAP SCR 0.38-16X3.75 HHGR5 4 21 0220 CAP SCR 0.25-20 X 1.50 HHGR5 5 11 0347 NUT 0.38-16 HH NYLOC 4 22 34622 PLUG PLASTIC 1.25X0.19 CCF1.5-14-20 4

Base Assembly (84-10) - PN 33337

Assembly Drawings 43

PN 34245

ITEM PART DESCRIPTION QTY. ITEM PART DESCRIPTION QTY. 1 34246 BASE WLDMT 108-12 FLEX36 1 12 0532 CAP SCR 0.38-16X3.75 HHGR5 4 2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4 13 0347 NUT 0.38-16 HH NYLOC 4 3 19291 ROLLER 4" OD 2 14 c1592 ZERK 1/8 NPT STRAIGHT 2 4 1546 THRUST WASHER 2.01DIA UHMW .12THK 6 15 C0078 HOSE CLAMP #8 RU BBER COATED 1 5 8819 BUSHING QSI-3235-16 2 16 0479 CAP SCR 0.25-20X0.75 HHGR5 1 6 23699 BUSHING 32DXR20 2.00X1.25 2 17 0333 NUT 0.25-20 HHGR5 NYLOC 1 7 33741 PIN 2.00X10.19 SR 1 18 0220 CAP SCR 0.25-20 X 1.50 HHGR5 5 8 0427 MACHY WASHER 2.00ID 10GA 2 19 0340 W ASHER 0.25 FLAT 5 90108 SNAP RING 2.00 7200-200 2 20 8622 CLAMP HOSE/TUBE AG-2 10 10 24766 PIN 2.00X47.00 1 21 34641 TUBE ASM 0.50X122.50 2 11 22764 COLLAR 2.01X3.00X1.00 4 22 34622 PLUG PLASTIC 1.25X0.19 CCF1.5-14-20 4

Base Assembly (108-12) - PN 34245

44 Flex36 Owner’s Manual

PN 33419

ITEM PART DESCRIPTION QTY. ITEM PART DESCRIPTION QTY. 1 33418 BASE WLDMT 120-14 FLEX36 1 12 0532 CAP SCR 0.38-16X3.75 HHGR5 4 2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4 13 0347 NUT 0.38-16 HH NYLOC 4 3 19291 ROLLER 4" OD 2 14 c1592 ZERK 1/8 NPT STRAIGHT 2 4 1546 THRUST WASHER 2.01DIA UHMW .12THK 6 15 C0078 HOSE CLAMP #8 RU BBER COATED 1 5 8819 BUSHING QSI-3235-16 2 16 0479 CAP SCR 0.25-20X0.75 HHGR5 1 6 23699 BUSHING 32DXR20 2.00X1.25 2 17 0333 NUT 0.25-20 HHGR5 NYLOC 1 7 33741 PIN 2.00X10.19 SR 1 18 8622 CLAMP HOSE/TUBE AG-2 12 8 0427 MACHY WASHER 2.00ID 10GA 2 19 34413 TUBE ASM 0.50X130.00 2 9 0108 SNAP RING 2.00 7200-200 2 20 0340 WASHER 0.25 FLAT 6 10 24766 PIN 2.00X47.00 1 21 0220 CAP SCR 0.25-20 X 1.50 HHGR5 6 11 22764 COLLAR 2.01X3.00X1.00 4 22 34622 PLUG PLASTIC 1.25X0.19 CCF1.5-14-20 4

Base Assembly (120-14) - PN 33419

Assembly Drawings 45

PN 31824

ITEM PART DESCRIPTION QTY. 1 31822 DUMP WLDMT 60-8 FLEX36 1 2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 6 3 22227 PIN 2.00X25.25 1 4 2257 SNAP RING INSIDE 2.00 2 5 33062 TAB LOADER WLDMT BREAK AWAY 1 6 0332 CAP SCR 0.31-18X1.75 HHGR5 2 7 23301 TAB LOADER BREAK AWAY 1 8 0506 CAP SCR 0.50-13X4.00 HHGR5 2 9 0333 NUT 0.25-20 HHGR5 NYLOC 2 10 C6106 NUT 0.50-13 HHGR5 NYLOC 2 11 26287 SWITCH PROXIMITY CARLO GAVAZZI 1 12 c1592 ZERK 1/8 NPT STRAIGHT 2

Dump Assembly (60-8) - PN 31824

46 Flex36 Owner’s Manual

PN 33339

ITEM PART DESCRIPTION QTY. 1 33340 DUMP WLDMT 84-10 FLEX36 1 2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 6 3 22227 PIN 2.00X25.25 1 4 2257 SNAP RING INSIDE 2.00 2 5 33062 TAB LOADER WLDMT BREAK AWAY 1 6 0332 CAP SCR 0.31-18X1.75 HHGR5 2 7 23301 TAB LOADER BREAK AWAY 1 8 0506 CAP SCR 0.50-13X4.00 HHGR5 2 9 0333 NUT 0.25-20 HHGR5 NYLOC 2 10 C6106 NUT 0.50-13 HHGR5 NYLOC 2 11 26287 SWITCH PROXIMITY CARLO GAVAZZI 1 12 c1592 ZERK 1/8 NPT STRAIGHT 2

Dump Assembly (84-10) - PN 33339

Assembly Drawings 47

PN 34247

ITEM PART DESCRIPTION QTY. ITEM PART DESCRIPTION QTY. 134248 DUMP WLDMT 108-12 FLEX36 1 7 0506 CAP SCR 0.50-13X4.00 HHGR5 2 2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 6 8 0332 CAP SCR 0.31-18X1.75 HHGR5 2 3 22227 PIN 2.00X25.25 1 9 0333 NUT 0.25-20 HHGR5 NYLOC 2 4 2257 SNAP RING INSIDE 2.00 2 10 C6106 NUT 0.50-13 HHGR5 NYLOC 2 5 33062 TAB LOADER WLDMT BREAK AWAY 1 11 26287 SWITCH PROXIMIT Y CARLO GAVAZZI 1 6 23301 TAB LOADER BREAK AWAY 1 12 c 1592 ZERK 1/8 NP T STRAIGHT 2

Dump Assembly (108-12) - PN 34247

48 Flex36 Owner’s Manual

PN 33417

ITEM PART DESCRIPTION QTY.

1 33416 DUMP WLDMT 120-14 FLEX36 1 2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 6 3 22227 PIN 2.00X25.25 1 4 2257 SNAP RING INSIDE 2.00 2 5 33062 TAB LOADER WLDMT BREAK AWAY 1 6 23301 TAB LOADER BREAK AWAY 1 7 0506 CAP SCR 0.50-13X4.00 HHGR5 2 8 0332 CAP SCR 0.31-18X1.75 HHGR5 2 9 0333 NUT 0.25-20 HHGR5 NYLOC 2 10 C6106 NUT 0.50-13 HHGR5 NYLOC 2 11 26287 SWITCH PROXIMITY CARLO GAVAZZI 1 12 c1592 ZERK 1/8 NPT STRAIGHT 2

Dump Assembly (120-14) - PN 33417

Assembly Drawings 49

PN 33047

ITEM PART DESCRIPTION QTY. 133048 SECONDARY WLDMT 60-8 FLEX36 1 227116 CYLINDER ASM 27020 4.00X29.63 1 3 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 6 4 22286 PIN 2.00X16.00 1 5 2257 SNAP RING INSIDE 2.00 2 6 0068 BUSHING QSI-1618-24 4 7 0069 BUSHING QSI-1618-16 4 8 22285 PIN 1.00X15.00 1 9 3875 SNAP RING 1.00 INTERNAL 2 10 c1592 ZERK 1/8 NPT STRAIGHT 2

Secondary Assembly (60-8) - PN 33047

50 Flex36 Owner’s Manual

PN 33341

ITEM PART DESCRIPTION QTY. 1 33342 SECONDARY WLDMT 84-10 FLEX36 1 2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 6 3 0069 BUSHING QSI-1618-16 4 4 3875 SNAP RING 1.00 INTERNAL 2 5 22285 PIN 1.00X15.00 1 6 22286 PIN 2.00X16.00 1 7 2257 SNAP RING INSIDE 2.00 2 8 0068 BUSHING QSI-1618-24 4 933404 CYLINDER ASM 5.50X40.00 1 10 c1592 ZERK 1/8 NPT STRAIGHT 2

Secondary Assembly (84-10) - PN 33341

Assembly Drawings 51

PN 34249

ITEM PART DESCRIPTION QTY. 134250 SECONDARY W LDMT 108-12 FLEX36 1 2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 6 3 0068 BUSHING QSI-1618-24 4 4 0069 BUSHING QSI-1618-16 4 5 3875 SNAP RING 1.00 INTERNAL 2 6 22285 PIN 1.00X15.00 1 7 22286 PIN 2.00X16.00 1 8 2257 SNAP RING INSIDE 2.00 2 933462 CYLINDER ASM 5.50X52.38 1 10 c1592 ZERK 1/8 NPT STRAIGHT 2

Secondary Assembly (108-12) - PN 34249

52 Flex36 Owner’s Manual

PN 33415

ITEM PART DESCRIPTION QTY. 133414 SECONDARY WLDMT 120-14 FLEX36 1 2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 6 3 0068 BUSHING QSI-1618-24 4 4 0069 BUSHING QSI-1618-16 4 5 3875 SNAP RING 1.00 INTERNAL 2 6 22285 PIN 1.00X15.00 1 7 22286 PIN 2.00X16.00 1 8 2257 SNAP RING INSIDE 2.00 2 933462 CYLINDER ASM 5.50X52.38 1 10 c1592 ZERK 1/8 NPT STRAIGHT 2

Secondary Assembly (120-14) - PN 33415

Assembly Drawings 53

PN 33049

ITEM PART DESCRIPTION QTY. ITEM PART DESCRIPTION QTY. 1 33050 TILT WLDMT FLEX36 1 7 33103 PIN WLDMT 1.00X10.50 2 2 23460 CYLINDER ASM 3.00X17.00 1 8 D0419 THRUST WASHER 2 3 0069 BUSHING QSI-1618-16 1 9 33104 COLLAR 1.03X2.00X1.00 2 4 0064 PIN 1.00X3.38 1 10 0339 CAP SCR 0.25-20X2.50 HHGR5 2 5 0110 SNAP RING 1.00 ID 7200-100 2 11 0333 NUT 0.25-20 HHGR5 NYLOC 2 6 0068 BUSHING QSI-1618-24 4 12 c1592 ZERK 1/8 NPT STRAIGHT 2

Tilt Assembly (All Flex36 Models) - PN 33049

54 Flex36 Owner’s Manual

ITEM PART DESCRIPTION QTY.

135033 TILT FLEX 36 54HH 1 235169 CYLINDER ASM 3.00X10.00 1 3 0110 SNAP RING 1.00 ID 7200-100 2 4 0068 BUSHING QSI-1618-24 8 533103 PIN WLDMT 1.00X10.50 2 6 D0419 T

HRUST WASHER 2 733104 COLLAR 1.03X2.00X1.00 2 8 0339 CAP SCR 0.25-20X2.50 HHGR5 2 9 0333 NUT 0.25-20 HHGR5 NYLOC 2

10 c1592 ZERK 1/8 NPT STRAIGHT 4 11 35066 PIN 1.00X18.38 SR 1 12 0867 MACHY WASHER 1.00ID 14GA 2

PN 35032

Tilt Assembly (Optional Tall Tilt) - PN 35032

Note: This tilt assembly requires a port side relief (PN 35408) installed in the valve bank on the retract side of the main cylinder. Please refer to the port side relief drawing for installation instruction.

PN 23460

ITEM PART DESCRIPTION QTY. 1 3767 CYLINDER 3.00X17.00 1 20279 FTG ADAPT 6-F5OLO-S 2 3 0068 BUSHING QSI-1618-24 2

Bushing shown as reference.

Tilt Cylinder Assembly (All Flex36 Models) - PN 23460

55Assembly Drawings 55

Note: This Tilt Cylinder uses Stellar Seal Kit P/N C6301.

56 Flex36 Owner’s Manual

PN 27116

ITEM PART DESCRIPTION QTY. 127020 CYLINDER 4.00X29.63 1 2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4 315822 MANIFOLD DOUBLE T11A 5000 PSI 1 427117 TUBE ASM 0.50X11.94 2 519369 HOSE CLAMP 4.13-7.00 5416K38 2 618701 CLAMP PORT TUBE ZR518 2 7 D1290 FTG ADAPT 8-6 F5OLO-S 6

Main Cylinder Assembly (60-8) - PN 27116

Note: This Main Cylinder uses Stellar Seal Kit P/N 32565.

Bushings shown as reference.

.YTQNOITPIRCSEDTRAPMETI

100.04X05.5 REDNILYC504331

1S-OLO5F-6 TPADA GTF

7202

3D1290 FTG ADAPT 8-6 F5OLO-S 5

415822 MANIFOLD DOUBLE T11A 5000 PSI 1

54381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4

.72X05.0 MSA EBUT447336

719369 HOSE CLAMP 4.13-7.00 5416K38 1

818701 CLAMP PORT TUBE ZR518 1

916256 TUBE ASM 0.50X6.75 MAIN CYL 60-10-8 1

PN 33404

Main Cylinder Assembly (84-10)- PN 33404

Note: This Main Cylinder uses Stellar Seal Kit P/N 35646.

57Assembly Drawings 57

58 Flex36 Owner’s Manual

Bushings shown as reference.

.YTQ

NOI

TPIRCSE

MET

183.25X05.5 REDNILYC364331

1S-OLO5F-6 TPADA GTF97

3D1290 FTG ADAPT 8-6 F5OLO-S 5

415822 MANIFOLD DOUBLE T11A 5000 PSI 1

54381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4

1.04

X05.0 MSA EBU

T05733

719369 HOSE CLAMP 4.13-7.00 5416K38 1

818701 CLAMP PORT TUBE ZR518 1

916256 TUBE ASM 0.50X6.75 MAIN CYL 60-10-8 1

PN 33462

Main Cylinder Assembly (108-12, 120-14)- PN 33462

Note: This Main Cylinder uses Stellar Seal Kit P/N 35646.

Chapter 8 - Replacement Parts

59Replacement Parts 59

Part#

C6229 C5552 15462 15463 C2028 C2029 D1244 D1246 D1247 D1249 27117 33744 33750 19369 34415 34418 34641 34413 18701 8622 C6184 37474 37475 37470 37473 37469 0108 2257 3875 C1592 26031 26287 C6072 35552 C6301 32565 35646 35556 35553 35554 35555 35557

Description

Hydraulic Filter Hydraulic Filter Strainer Fill Cap Asm Thermo Sight Gauge O Ring #6 Face Seal O Ring #8 Face Seal O Ring #12 Face Seal O Ring #6 SAE O Ring #8 SAE O Ring #12 SAE Port Tube Asm (Main Cyl) Port Tube Asm (Main Cyl) Port Tube Asm (Main Cyl) Hose Clamp (Cyl) Port Tube Asm (Base Cyl) Port Tube Asm (Base Cyl) Port Tube Asm (Base Cyl) Port Tube Asm (Base Cyl) Clamp Port T Clamp Hose/Port Tube (Base Cyl) C-Balance Valve (Cyl) Control Lever Right Bend Control Lever Left Bend Control Console Control Cable 16’ Cable Hook-up Kit Snap Ring 2.00” External Snap Ring 2.00” Internal Snap Ring 1.00” Internal Grease Zerk 1/8 NPT Tab Alarm Proximity Switch Bosch Relay Seal Kit (Rotary Valve) Seal Kit (Tilt Cyl) Seal Kit (Main Cyl) Seal Kit (Main Cyl) Bushing Kit (Tilt Asm) Bushing Kit (Base Asm) Bushing Kit (Dump Asm) Bushing Kit (Secondary Asm) Bushing Kit (Complete Asm)

ube (Cyl)

Where Used

60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 84-10 108-12/120-14 60-8 thru 120-14 60-8 84-10 108-12 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 84-10 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14 60-8 thru 120-14

Call 800-321-3741 to Order

60 Flex36 Owner’s Manual

Chapter 9 - Troubleshooting

roblem: Hydraulic system gets extremely hot.

This chapter will list a number of

potential problems that may occur

while operating the Hooklift. Most

problems are easily solved using the

solutions portion of this chapter. If

problems persist, please contact

Customer Service at Stellar Industries

1-800-321-3741.

Problem: Hooklift will not operate or operates slow.

Solutions:

• Make sure the PTO is engaged.

• Make sur actuator are shifting the spool valves on the valve section

• Make sure that the hydraulic pump is operating at its rated flow or GPMs under load. Check the flow by using a flow meter to determine the GPMs. To find the proper flow the equipment is to operate at, see Chapter 6 of the Hooklift Owner’s Manual.

• Make sure the relief pressure is properly set per the specifications page of the hooklift owners manual.

• Make sure the spool valves on the valve bank are adjusted and operating smoothly.

Problem: Lift cylinder operates, but the tilt cylinder operates slow or does not operate at all.

Solutions:

• Make sure the rotary valve arm is properly adjusted. See Rotary Valve Drawing in the Installation Chapter of this manual.

• Make sure the rotary valve arm is not damaged or has become disconnected.

e the control lever/cable assembly or air

Solutions:

• Make sure the hydraulic filter has been changed per the maintenance page of the Hooklift Owner’s

anual.

• Make sure the filter strainer of the hydraulic reservoir is not plugged.

• Make sure that the hydraulic pump is operating at its rated flow or GPMs.

• Make sure the relief pressure is set properly. See Table 1.1 of Chapter 6: Installation for proper setting.

Problem: Hooklift will not lift or pickup a loaded container. Solutions:

• Make sure the container contents are evenly distributed.

• Make sur exceed the rated capacity.

• Make sure the relief pressure is properly set per Table 1.1 in the Installation Chapter of this manual.

• Make sure the hydraulic pump is operating at its rated flow or GPMs. See Chapter 4: Specifications.

• Make sure that the container is not fixed to the ground or frozen down.

Problem: Dump weldment lifts upward while picking up a container. Solutions:

• Make sure the rear hooklift rollers spin freely and smoothly.

• Make sure the body hold down brackets are not n or bent.

wor

Problem: Tab alarm sounds off inside chassis cab.

Solutions:

• Break away tabs on dump weldment have broken

loose. Re-install break away tabs using a Grade 5 5⁄16” bolt.

e the container and its load does not

61Troubleshooting 61

Problem: Cylinders drift upward or downward while hydraulics are dis-engaged. Solutions:

• Make sure valve spools are shifting to three neutral position.

• Possible contamination keeping the holding valve open.

• Possible internal piston seals rolled or damaged.

Problem: Hooklift binds at pivot points. Solutions:

• Make sure the pivot points are lubricated.

• Make sure pivot pins are not seized to the bushing.

• Make sur

aligned or bent.

e the weldments or pins ar

Contact Customer Service at Stellar Industries: 1-800-321-3741

e not mis-

Limited Warranty Statement

Stellar Industries, Inc. (Stellar) warrants products designed and manufactured by Stellar to be free from defects in material and workmanship under proper use and maintenance. Products must be installed and operated in accordance with Stellar’s written instructions and capacities. The warranty period shall cover the following:

Twelve (12) month warranty on parts from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) months from date of manufacture, Twelve (12) month repair labor from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) month from date of manufacture, and Thirty-six (36) month warranty on all Stellar Crane and Hooklift structural parts from the date recorded by Stellar as the in-service date, not to extend beyond forty-eight (48) months from date of manufacture.

The in-service date will be derived from the completed warranty registration card. In the event a warranty registration card is not received by Stellar, the factory ship date will be used.

Stellar’s obligation under this warranty is limited to, and the sole remedy for any such defect shall be, the repair and/or replacement (at Stellar’s option) of the unaltered part and/or component in question. Stellar after-sales service personnel must be notified by telephone, fax, or letter of any warranty-applicable damage within fourteen (14) days of its occurrence. If at all possible, Stellar will ship the replacement part within 24hours of notification by the most economical, yet expedient, means possible. Expedited freight delivery will be at the expense of the owner.

Warranty claims must be submitted and shall be processed in accordance with Stellar’s established warranty claim procedure. Stellar after-sales service personnel must be contacted prior to any warranty claim. A return materials authorization (RMA) account number must be issued to the claiming party prior to the return of any warranty parts. Parts returned without prior authorization will not be recognized for warranty consideration. All damaged parts must be returned to Stellar freight prepaid; freight collect returns will be refused. Freight reimbursement of returned parts will be considered as part of the warranty claim.

Warranty service will be performed by any Stellar new equipment distributor, or by any Stellar-recognized service center authorized to service the type of product involved, or by the Stellar factory in the event of a direct sale. At the time of requesting warranty service, the owner must present evidence of date of delivery of the product. The owner shall be obligated to pay for any overtime labor requested of the servicing company by the owner, any field service call charges, and any towing and/or transportation charges associated with moving the equipment to the designated repair/service provider.

All obligations of Stellar and its authorized dealers and service providers shall be voided if someone other than an authorized Stellar dealer provides other than routine maintenance service without prior written approval from Stellar. In the case repair work is performed on a Stellarmanufactured product, original Stellar parts must be used to keep the warranty in force. The warranty may also be voided if the product is modified or altered in any way not approved, in writing, by Stellar.

The owner/operator is responsible for furnishing proof of the date of original purchase of the Stellar product in question. Warranty registration is the ultimate responsibility of the owner and may be accomplished by the completion and return of the Stellar product registration card provided with the product. If the owner is not sure of registration, he is encouraged to contact Stellar at the address below to confirm registration of the product in question. This warranty covers only defective material and workmanship. It does not cover depreciation or damage caused by normal wear and tear, accident, mishap, untrained operators, or improper or unintended use. The owner has the obligation of performing routine care and maintenance duties as stated in Stellar’s written instructions, recommendations, and specifications. Any damage resulting from owner/operator failure to perform such duties shall void the coverage of this warranty. The owner will pay the cost of labor and supplies associated with routine maintenance.

The only remedies the owner has in connection with the breach or performance of any warranty on the Stellar product specified are those set above. In no event will Stellar, the Stellar distributor/dealer, or any company affiliated with Stellar be liable for business interruptions, costs of delay, or for any special, indirect, incidental, or consequential costs or damages. Such costs may include, but are not limited to, loss of time, loss of revenue, loss of use, wages, salaries, commissions, lodging, meals, towing, hydraulic fluid, or any other incidental cost.

All products purchased by Stellar from outside vendors shall be covered by the warranty offered by that respective manufacturer only. Stellar does not participate in, or obligate itself to, any such warranty.

Stellar reserves the right to make changes in design or improvement upon its products without imposing upon itself the same upon its products theretofore manufactured.

This warranty will apply to all Stellar Hooklifts, Stellar Service Trucks, & Truck-mounted Cranes shipped from Stellar’s factory after July 1, 2005. The warranty is for the use of the original owner only and is not transferable without prior written permission from Stellar.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THE PROVISION OF MATERIAL AND SERVICES, AS SPECIFIED HEREIN. STELLAR INDUSTRIES, INC. IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Revision Date: February 2007 Document Number: 37040

Stellar Flex36 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

Chapter 1 - Safety

General Safety

Personal Safety

Maintenance Safety

Stability

Load Safety

Environment

Chapter 2 - Operation

Job-Site Set-Up

Operator Requirements

Operator Conduct

Hooklift Controls

Operation Overview

Unloading Operation

Loading Operation

Dumping Operation

Chapter 3 - Maintenance

Maintenance Procedures

Periodic Inspection

Daily Inspection

Monthly Inspection

General Service

Chapter 4 - Specifications

Chapter 5 - Decals

Decals of Note

Decal Kit Placement - PN 35559

Chapter 6 - Installation

Basic Installation Overview

Reservoir Assembly - PN 35883

Setting System Relief Pressure

Port Side Relief Installation

Controller Assembly - PN 38841

Dump Light Kit Installation

Subframe Model 60-8

Subframe Model 84-10

Subframe Model 108-12

Subframe Model 120-14

Chapter 7 - Assembly Drawings

Base Assembly (60-8) - PN 31823

Dump Assembly (60-8) - PN 31824

Chapter 8 - Replacement Parts

Chapter 9 - Troubleshooting